Process for encapsulating glass fiber insulation

Abstract

Encapsulated glass fiber insulation is made by forming a covering material over the top surface of a mineral fiber core, with the formed covering material extending adjacent the side surfaces. The covering material is greater in width than the sum of the widths of the top and two side surfaces, so that the edges of the formed covering material extend beyond the mineral fiber core. A vacuum is applied below the mineral fiber core to draw the formed covering material extending beyond the side surfaces under the core.

We claim: 
     
       1. A process for encapsulating compressible mineral fiber insulation, the process comprising: a) providing a longitudinally extending mineral fiber core having opposed major, top and bottom surfaces, and opposed side surfaces;   b) forming a covering material over the top surface, the formed covering material extending adjacent the width than the sum of thing material being greater in width than the sum of the widths of the top and two side surfaces, the edges of the formed covering material extending below the side surfaces;   c) providing a vacuum under the mineral fiber core to draw the formed covering material extending below the side surfaces, including the edges of the covering material, under the core and adjacent the bottom major surface.   
     
     
       2. A process according to claim 1 further comprising: d) providing a facing material adjacent the bottom major surface; and   e) adhering the facing material to the bottom major surface.   
     
     
       3. A process according to claim 1 wherein a continuous web of the covering material is formed over a continuously moving glass fiber core using a web former. 
     
     
       4. A process according to claim 3 wherein the top and side surfaces of the covering material are pulled by a vacuum towards the core to conform to the shape of the core. 
     
     
       5. The process of claim 1, wherein the vacuum is drawn from a vacuum draw means. 
     
     
       6. A process according to claim 1 further comprising pressing the covering material drawn adjacent the major bottom surface by the applied vacuum into contact with the bottom major surface using a heated roll. 
     
     
       7. A process for encapsulating compressible mineral fiber insulation, the process comprising: a) providing a continuously moving longitudinally extending mineral fiber core having opposed major, top and bottom surfaces, and opposed side surfaces;   b) forming a continuous web of covering material over the top surface, the formed covering material extending adjacent the side surfaces, the covering material being greater in width than the sum of the widths of the top and two side surfaces, the edges of the formed covering material extending below the side surfaces, the continuous web being formed using a web former; and   c) providing a vacuum under the mineral fiber core to draw the formed covering material extending below the side surfaces, including the edges of the covering material, under the core and adjacent the bottom major surface.   
     
     
       8. A process for encapsulating compressible mineral fiber insulation, the process comprising: a) providing a continuous moving longitudinally extending mineral fiber core having opposed major, top and bottom surfaces, and opposed side surfaces;   b) forming a continuous web of covering material over the top surface, the formed covering material extending adjacent the side surfaces, the covering material being greater in width than the sum of the widths of the top and two side surfaces, the edges of the formed covering material extending below the side surfaces, the continuous web being formed using a web former; and   c) providing a vacuum under the mineral fiber core to draw the formed covering material extending below the side surfaces, including the edges of the covering material, under the core and adjacent the bottom major surface, the top and side surfaces of the covering material being pulled by a vacuum towards the core to conform to the shape of the core.